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D2 - Transmission Gearboxes, diffs, drive shafts.

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Old 15th November 2016, 09:04 AM
HPsauce HPsauce is offline
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Having not had an XP PC for a while now, my Bentley manual has been "retired" (hibernated).
But last night I installed Oracle Virtualbox and XP within it then fired up Bentley for the D2 S8.

Today I'll be retrieving a proper XP machine so that I can print everything off easily, but in summary it says:
1. Remove Left Transmission Support complete (do not separate mount and support)
3. Disconnect F125 and pull off shaft
4. Attach replacement, with several notes on alignment, centring, not tilting, not forcing etc.
5. Reinstall Left Transmission Support

There are torque figures for all:
F125 to transmission - 8Nm
Transmission support to transmission - 42Nm
Transmission mounting to subframe - 40Nm

It also clarifies that if ONLY one Support is removed the other will suffice to hold the transmission in place, otherwise you need a lift under it (VAG1383A)

I think, as the Audipages document makes clear that's a lot worse than it sounds!
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions and extended leather. Ski hatch retrofit. Aftermarket reversing camera. DVB-T and XCarlink now removed as redundant.
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (Even rarer than a D2 S8!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. Agate Grey/Platinum. Every option (I think) except electric rear seats, Tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon. Added Auto-dim mirror, Leather seats, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #2  
Old 15th November 2016, 09:33 AM
HPsauce HPsauce is offline
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Managed to get the relevant pages off as PDF's. Attached.
Attached Files
File Type: pdf F125.pdf (58.5 KB, 362 views)
File Type: pdf Trans.pdf (119.2 KB, 313 views)
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions and extended leather. Ski hatch retrofit. Aftermarket reversing camera. DVB-T and XCarlink now removed as redundant.
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (Even rarer than a D2 S8!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. Agate Grey/Platinum. Every option (I think) except electric rear seats, Tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon. Added Auto-dim mirror, Leather seats, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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Old 15th November 2016, 09:47 AM
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David's8 David's8 is offline
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One of the major issues as the Audipages "how-to" points out and my garage found is getting clearance from the exhaust to get access to some of the bolts. It requires some brute force.
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2002 D2 S8 – Ming Blue, Valcona leather, Vavona wood insert, solar sunroof (to be fitted), Heated rear seats, extended leather pack, 18” Avus, ski hatch, Bose, auto dim rear view mirror, rear blind.
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Old 15th November 2016, 10:08 AM
MikkiJayne MikkiJayne is offline
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Quote:
Originally Posted by HPsauce View Post
It also clarifies that if ONLY one Support is removed the other will suffice to hold the transmission in place, otherwise you need a lift under it (VAG1383A)
That is optimistic in the extreme! You can't get the mount out with weight on it, so you have to jack up the back of the transmission to remove it. I found that out when I forgot to re-attach the shifter cable after putting the engine back in the first time

The bolt behind the downpipe is going to require a special took I think. Its actually not that painful to move that downpipe on mine as I have the SAI removed so I can get to the top manifold bolt, but on a stock car you'd really want to do it without moving the downpipe so you need a super-short T27 I think.

As the Titanic is still on the lift (don't ask) I can't check for a week or two so I'm just going to have to live with it on mine for a bit
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Old 15th November 2016, 10:28 AM
HPsauce HPsauce is offline
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Quote:
Originally Posted by MikkiJayne View Post
That is optimistic in the extreme! You can't get the mount out with weight on it, so you have to jack up the back of the transmission to remove it.
I did wonder that myself, but then I didn't write this stuff.

I've printed off the Audipages guide to give to the garage on Friday, along with Bentley.
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions and extended leather. Ski hatch retrofit. Aftermarket reversing camera. DVB-T and XCarlink now removed as redundant.
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (Even rarer than a D2 S8!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. Agate Grey/Platinum. Every option (I think) except electric rear seats, Tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon. Added Auto-dim mirror, Leather seats, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #6  
Old 15th November 2016, 12:37 PM
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David's8 David's8 is offline
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Quote:
Originally Posted by HPsauce View Post
I did wonder that myself, but then I didn't write this stuff.

I've printed off the Audipages guide to give to the garage on Friday, along with Bentley.
I did that as well but you may need to point out the fact that its written for a LHD - the mechanic who actually did some of the work initially disregarded it as it "was wrong" as it states the switch was on the "drivers side of the car". he was quickly put right by the senior guy.

The Audipages guide certainly makes it clear in step 6 that the transmission needs supporting with a jack.
I attach a pdf precis of the guide which I made which cuts it down to 8 pages and easier for printing. All steps are there, its just resized the pictures and cut out some introductory waffle. I also changed it to reflect the 10pin rectangular plug on the later cars although the picture still shows the 8 pin round one.
Attached Files
File Type: pdf F125 Transmission Switch Replacement.pdf (1.57 MB, 709 views)
__________________
2002 D2 S8 – Ming Blue, Valcona leather, Vavona wood insert, solar sunroof (to be fitted), Heated rear seats, extended leather pack, 18” Avus, ski hatch, Bose, auto dim rear view mirror, rear blind.
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  #7  
Old 15th November 2016, 01:34 PM
HPsauce HPsauce is offline
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Thanks David, I had already annotated my printout accordingly, though I think they do actually know where it is.
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions and extended leather. Ski hatch retrofit. Aftermarket reversing camera. DVB-T and XCarlink now removed as redundant.
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (Even rarer than a D2 S8!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. Agate Grey/Platinum. Every option (I think) except electric rear seats, Tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon. Added Auto-dim mirror, Leather seats, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #8  
Old 16th November 2016, 10:01 PM
HPsauce HPsauce is offline
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Just a little footnote.

Having set up Bentley inside XP inside Oracle Virtualbox I remembered that long ago some kind person here (sorry but I've forgotten who!) gave me a copy of Elsawin (v3.60?) running inside an older version of Virtualbox.
To my shame I'd never really delved into it and with PC changes and upgrading to W10 never reloaded it.

So I found it, copied the virtual disk file (.vdi) across and quickly set up a second virtual PC to run it. Works a treat.
(Just need to put it on the laptop now, alongside VCDS and Bentley, and learn how to use it)

The point of this is (finally) that I then looked up, in Elsawin, the procedure for replacing the F125 switch.
And sadly (but not surprisingly) it's exactly the same, and just as brief, as in Bentley.
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions and extended leather. Ski hatch retrofit. Aftermarket reversing camera. DVB-T and XCarlink now removed as redundant.
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (Even rarer than a D2 S8!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. Agate Grey/Platinum. Every option (I think) except electric rear seats, Tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon. Added Auto-dim mirror, Leather seats, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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